EP1901149A2 - Procédé et dispositif destinés à la simulation de l'usinage d'une pièce sur une machine-outil - Google Patents

Procédé et dispositif destinés à la simulation de l'usinage d'une pièce sur une machine-outil Download PDF

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Publication number
EP1901149A2
EP1901149A2 EP07017075A EP07017075A EP1901149A2 EP 1901149 A2 EP1901149 A2 EP 1901149A2 EP 07017075 A EP07017075 A EP 07017075A EP 07017075 A EP07017075 A EP 07017075A EP 1901149 A2 EP1901149 A2 EP 1901149A2
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EP
European Patent Office
Prior art keywords
data
plc
machine tool
cnc
simulation
Prior art date
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Granted
Application number
EP07017075A
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German (de)
English (en)
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EP1901149A3 (fr
EP1901149B1 (fr
Inventor
Rudolf Hahn
Manfred Herz
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DMG Electronics GmbH
Original Assignee
DMG Electronics GmbH
Deckel Maho Pfronten GmbH
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Publication of EP1901149A2 publication Critical patent/EP1901149A2/fr
Publication of EP1901149A3 publication Critical patent/EP1901149A3/fr
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Program-control systems
    • G05B19/02—Program-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of program data in numerical form
    • G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of program data in numerical form characterised by monitoring or safety
    • G05B19/4069—Simulating machining process on screen
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/10—Plc systems
    • G05B2219/13—Plc programming
    • G05B2219/13174—Pc, computer connected to plc to simulate machine
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/35—Nc in input of data, input till input file format
    • G05B2219/35309—Actual execution times acquired during machining used in simulation

Definitions

  • the present invention relates to an apparatus and a method for simulating a sequence for machining a workpiece on a machine tool.
  • the simulation of processes on CNC (computerized numerical control) machines is made possible.
  • CNC is a numerical control that includes one or more microprocessors for the execution of control functions. Outer features of a CNC are a computer screen and a keyboard.
  • the numerical control (CNC) is operated with a CNC program that includes all the necessary functions, such as interpolation, position and speed control. With the help of the one or more microprocessors and the CNC program, a workpiece-dependent CNC part program is executed, which is usually specified by the user of the machine.
  • a fitting program is also required for the machine to be controlled, which the machine manufacturer creates and integrates into a programmable logic controller (PLC) , It defines all machine-related links and interlocks for special function sequences, such as tool changes, workpiece changes and axis limitations.
  • a CNC part program for machining the workpieces is created by the machine user. CNC part programs can be changed or modified as desired by the user.
  • a PLC program is created by the machine manufacturer and stored permanently, for example on a ROM (read only memory). The PLC program only has to be changed or exchanged in exceptional cases. In particular, the PLC does not program during operation. PLC programs must be created for each PLC (programmable logic controller) and can not be compiled for other PLC makes. Based on this central difference, it can be seen that there can be up to several thousand CNC part programs per machine.
  • the CNC part programs are created by the machine user, fixed cycles and subroutines can certainly be supplied by the manufacturer. As a rule, there is only one single PLC fixed, plant-related program. The program is created by the machine manufacturer, usually using available function blocks.
  • Simulation systems for simulating the removal of a workpiece by a machine tool are known from the prior art.
  • the workpiece and the removal made on it by the machine tool are visualized three-dimensionally.
  • the visualized workpiece can be viewed from different angles.
  • EP 0 902 343 An example of the prior art described above is in EP 0 902 343 disclosed.
  • the system described therein allows the creation of a CNC part program for a virtual workpiece using at least one virtual functional unit.
  • the user can specify virtual actions by means of a data input device in this system.
  • the predetermined virtual actions on the virtual functional units are automatically converted into collision-free actions permitting control data sets of the control program, taking into account a given machine and control configuration.
  • the user does not need to know the machine and control configuration.
  • the complexity inherent in the machine and control configuration is shifted from the user to the data processing device, so that the user has the opportunity to concentrate exclusively on the virtual actions and virtual functional units to be specified.
  • the object is to provide an apparatus and a method for the simulation of processes on machine tools, which enable an improved simulation of movements of machine tools.
  • this object is achieved by a device having the features of claim 1, by a method having the features of claim 47 and a computer program product having the features of claim 93. Furthermore, the invention comprises a method for creating PLC machine tool sequence data with the The features of claim 94 and a PLC run simulator having the features of claim 95, which may be configured as a computer program product having the features of claim 96 to assist in achieving the above object.
  • the invention describes a device for simulating a sequence for machining a workpiece on a machine tool.
  • this device comprises a first memory device for storing machine tool data for generating a virtual image of a machine tool, a second memory device for storing workpiece data for generating a virtual image of at least one workpiece and a third memory device for storing resource data for generating a virtual image of at least one operating means ,
  • These devices provide the data necessary for generating a realistic image of the machine tool. This does not just include a representation of the Tool table and the workpiece, but also the ability to represent the clamping situation in detail during the simulation. Furthermore, it is possible to present the machine tool in various configurations, eg including the protective cabin, ie as a view from outside, or in a close-up view for the exclusive representation of the tool table together with workpiece and tool.
  • the corresponding data are supplied from the corresponding devices to the overall simulation device. This is virtually a pre-equipped with workpiece and tool machine tool.
  • a particularly close-to-reality representation of a machining process of a workpiece on a machine tool is realized according to the invention by providing a CNC control device, a PLC control device and a PLC sequence simulation device which perform the necessary data exchange with one another.
  • the CNC control device generates depending on the control data, which are provided by a corresponding means such as an input device by the user or a data carrier, CNC data corresponding to the corresponding control signals to the machine tool and / or the corresponding states of the machine tool.
  • PLC control unit for generating PLC control output data and a PLC-Ablaufsimulations founded for generating PLC simulation data and PLC control input data depending on the PLC control output data and the machine tool data realized.
  • the task of the PLC control unit is to generate PLC control output data. These can be called up, for example, by means of corresponding blocks of a CNC part program and correspond to the commands that are based on Obtain processing conditions of the machine tool.
  • the PLC run simulation device generates PLC control input data that notifies the PLC controller of the operating state of the machine tool. This allows the description of a complete flow of machining operations, including the commands issued by the CNC and PLC control.
  • the PLC sequence simulation device generates PLC simulation data describing the PLC-controlled motion sequences.
  • the overall simulation device receives the PLC simulation data and the CNC data and thus, in combination with the CNC control device, the PLC control device and the PLC sequence simulation, for the first time makes it possible to simulate all motion sequences executable on a real machine tool.
  • a structure is provided by the device according to the invention, which makes it possible in a simple manner to implement all functions, as they are given on a real machine tool, in the simulation. For example, by suitable modules, machining functions such as e.g. Override or manual traversing of table, head and spindle can be shown in the simulation.
  • machining functions such as e.g. Override or manual traversing of table, head and spindle can be shown in the simulation.
  • the interaction between the CNC controller, the PLC controller, the PLC schedule simulator, and the overall simulation apparatus realizes a holistic simulation approach, on the basis of consideration
  • the corresponding sub-functions during machining of the workpiece a particularly realistic simulation can be provided.
  • the simulation device is able to perform tasks that were previously closed to conventional simulation approaches. For example, all impending collisions can be detected, in particular the collisions that can be caused by PLC operations.
  • the automatic replacement of tools (tool automation) and the automatic replacement of workpieces (workpiece automation) can also be simulated. In this way it is e.g. possible to detect collisions that are based on the fact that a tool change is to be made with the flap closed to the tool magazine that a tool is to be included in the spindle, although there is still another tool is clamped, or that a tool removed from the spindle in Tool magazine is to be inserted in a place where another tool is already located.
  • the pallet storage which may be constructed, for example, in a circle or in a rack shape, to be simulated. Collisions can be detected, e.g. caused by a workpiece being clamped incorrectly on the pallet so that a collision would occur upon insertion of the pallet into the machine tool.
  • the simulation device in that the PLC control device is able to map the behavior of a real PLC control and interacts with a PLC flow simulation device, which makes it possible to realistically estimate the time behavior of the PLC sequences simulate. Since much of the cost of producing a workpiece is related to the machine usage times, it is determined by the Simulation device according to the invention possible to quickly and accurately make cost forecasts for the production of a workpiece.
  • the CNC controller comprises a CNC program generated from the source code of a CNC program of a real CNC controller.
  • this CNC program is used in the high-level language in this embodiment, and it is from a version of the CNC program generated, which is executable on a standard computer. This ensures that the CNC control device is an exact replica of the real CNC control device that can run on a PC.
  • the PLC control means comprises a PLC program of a real PLC control or a PLC program generated from the source code of a PLC program of a real PLC controller.
  • the background here is similar to the CNC program.
  • the PLC program of the real PLC control can be directly executed by the PLC controller, in this embodiment, the PLC program of the real PLC controller is adopted without changes.
  • manufacturers of PLC controllers program the PLC program in a high-level language and compile this program for the operating system of the PLC controller.
  • the means for providing control data comprises a memory device for storing at least one CNC part program, wherein the CNC part program can be executed on a real machine tool.
  • the means for providing control data further comprises an input means for manually inputting control data by the user to change the operating state of the machine tool.
  • This input device has the advantage that the user can manually input control commands, which are then reproduced as part of the overall simulation. For example, he can virtually open the door of the machine tool chamber, can manually move the head and spindle or can start or stop the coolant supply.
  • This functionality makes it possible to train operators for CNC machines. In the learning process, learners can not damage the machine tool because it is only simulated. Nevertheless, the virtual image of the machine tool is realistic. All manual inputs that a user would or should enter on a real machine tool can also be entered on the simulated machine tool. This makes a very realistic, yet cost-effective and risk-free training possible.
  • the input device comprises an override input device for inputting an override as a ratio between the feed or rotational speed according to the CNC part program and the changed feed or rotational speed when executing the CNC part program on the machine tool.
  • the override knob of a real machine tool is modeled.
  • a user of a CNC machine tool initially has a newly installed CNC part program run slower in order to be able to control the sequence better and, if necessary, to prevent collisions.
  • the input device comprises a manual travel path input device for inputting control data for manual movement of spindle, head and / or table.
  • this manual travel path input device the user of the simulation can manually move the spindle, the head and / or the table, as on a real machine tool.
  • the simulation realistically depicts a real machine tool.
  • the input device may comprise a clamping input device for inputting control data for clamping workpieces.
  • This chucking input device allows the user of the simulation to practice clamping workpieces and to prepare the virtual image of the machine tool for running a CNC part program.
  • the input device preferably includes a zero point setting input means for setting a zero point.
  • a zero point setting input means for setting a zero point.
  • the user of the Simulation how to set zero points on a real machine tool.
  • the definition of a workpiece zero in operational practice plays a major role.
  • the zero-point setting input device the setting of zero points can be practiced by the user.
  • the input device comprises a switch-on input device for manually inputting control data which are to be input by the operator of the machine tool after switching on a real machine tool in order to achieve a ready operating state of the machine tool.
  • this switch-on procedure input device it is possible to carry out all the manual inputs which are necessary on a real machine tool in order to bring the machine tool into an operational state after the machine tool has been switched on.
  • These switch-on processes may include, for example, the opening and closing of the door in order to insert a workpiece, the clamping of workpieces, etc.
  • the input device comprises a real control panel of a real machine tool, which preferably comprises a CNC control panel and / or a PLC control panel. Due to the inventive combination of the real control panel on the one hand and the simulation of the invention enabled holistic simulation of machining operations on the other hand, the user can be suggested a reality nearness that could not be approached so far, since he immediately gets the impression that he works on a real machine tool , This, for example, makes realistic training possible.
  • the input device may include a virtual control panel as a virtual image of a real control panel.
  • the virtual Control panel is preferably operated by a connected mouse or via a pressure-sensitive monitor.
  • the virtual control panel can also create a realistic operating situation for users who do not want to buy a real control panel.
  • the PLC controller may generate PLC control output data in response to the control data. This has the advantage that control data entered via the input device, such as the command to open the door of the machine tool chamber, can be executed by the PLC control device.
  • the device according to the invention is set up to enable the selection of a set within the CNC part program via the input device, wherein the total simulation device generates the total simulation data from the beginning of the CNC part program and the visualization device visualizes the simulation data starting from the selected set, so as to represent the process of machining a workpiece on the machine tool from the selected set.
  • a set within the CNC part program can be selected via the input device.
  • the user then signals that he would like to see the movement sequence from this sentence.
  • the part program is run through in a kind of fast pass from the beginning.
  • the visualization only starts from the selected sentence. This possibility to start the visualization on selectable sentences opens up new didactic possibilities in the field of training.
  • the display device comprises a real CNC display device of a real machine tool. This further enhances the user's feeling of being on a real machine tool. A more realistic training is possible.
  • the display device may comprise a virtual CNC display device as a virtual image of a real CNC display device of a real machine tool. This means that a real CNC display is mimicked on a commercial screen. As a result, a realistic training situation is created, even if no real CNC display device is available.
  • the visualization device is preferably set up to visualize the overall simulation data in three dimensions. This creates a realistic impression.
  • the first memory device comprises a device for storing kinematics data for describing the kinematic behavior of the machine tool.
  • the kinematic data contains information describing how the machine tool behaves in motion.
  • the kinematic data may include, for example, execution times for certain movement sequences.
  • the first memory device may comprise a device for storing machine tool element data for generating a virtual image of machine tool elements.
  • the first memory device may comprise a device for storing configuration data for generating a virtual image of the machine tool as a function of the machine tool element data, the kinematic data and the configuration data.
  • composition of a virtual image of the machine tool from individual machine tool elements with the aid of the configuration data makes it possible to represent different types of machine tools particularly efficiently, because many machine elements are identical on different types of machine tools.
  • the configuration data thus indicate how previously defined machine elements are to be combined in order to arrive at a complete machine model.
  • the third memory device comprises a device for storing tool data for generating a virtual image of at least one tool. This has the advantage that the tools can be modeled that uses the machine tool.
  • the third memory device preferably comprises a device for storing tensioning device data for generating a virtual image of at least one tensioning device. This makes it possible that the clamping means in which the workpieces are clamped, modeled.
  • the device according to the invention comprises a parameterization device for parameterizing the CNC control device and / or the PLC control device.
  • this parameterization device is set up for the CNC control device and / or the PLC control device with regard to at least one parameter from the group of travel range parameters, Parameterize control behavior parameters, compensation parameters and tool magazine parameters.
  • This parameterization device makes it possible to parameterize the CNC control device and / or the PLC control device such as real CNC controls and / or PLC controls.
  • the device according to the invention detects an interface for communication between the CNC control device and the overall simulation device.
  • This interface can be realized on the basis of a middleware, such as DCOM or CORBA (Common Object Request Broker Architecture).
  • the interface for communication between the CNC control device and the overall simulation device is preferably set up to convert non-object-oriented CNC data, which receives the interface from the CNC control device, into an object-oriented form prior to transfer to the overall simulation device.
  • OpenGL is object-oriented.
  • many CNC programs of common CNC control devices are programmed in C, i. H. in a non-object oriented language. Therefore, it is necessary to convert non-object-oriented CNC data into an object-oriented form in order to establish interoperability between the CNC controller and the visualization device.
  • the interface for communication between the CNC control device and the overall simulation device comprises a filter device that filters the amount of CNC data that the CNC control device sends to the interface, such that the total simulation device extracts only a subset of the quantity of the CNC control device receives transferred CNC data.
  • the CNC controller may be configured to provide new CNC data every 15 milliseconds. If all CNC data were transferred to the overall simulation device, then this total simulation device would have to update the machine tool model every 15 milliseconds. This computational effort can hardly be accomplished in 15 milliseconds, so that real-time simulation becomes very difficult.
  • the filter device only a subset of the CNC data is transferred to the overall simulation device, for example, the CNC data are passed to the total simulation device every 150 milliseconds, d. H. every tenth CNC record. Also, if only every tenth CNC data set is transferred, the movement sequence of the machine tool can be fully understood. The overall simulation device, however, less frequently has to update the machine tool model, so that less computational effort is necessary and real-time simulation becomes possible.
  • the device according to the invention comprises an input device for inputting configuration data for configuring the filter device.
  • this input device can be determined, for example, how much the filter device to filter the CNC data. There, for example, it can be entered that every fifth CNC data set or every fifteenth CNC data record is to be transferred to the overall simulation device.
  • the interface for communication between the CNC controller and the overall simulation device comprises synchronization means for synchronizing communication between the CNC controller and the overall simulation device.
  • the device according to the invention comprises an interface for communication between the PLC control device and the PLC sequence simulation device.
  • this interface is adapted to enable synchronization between the PLC controller and the PLC scheduling means by means of a semaphore.
  • the interface may include a synchronization device having a memory device that ensures that the PLC control device writes all the PLC control output data generated in one period to the memory device before the PLC run simulation device reads out the PLC control output data from the memory device.
  • the interface may include a synchronization device with a memory device that ensures that the PLC execution simulator writes all the PLC control input data generated in one period to the memory device before the PLC controller reads out the PLC control input data from the memory device.
  • the PLC controller always first writes a complete set of PLC control output data before the PLC execution simulator reads it out.
  • an atomicity of all output data of a period is achieved. This is desirable in order to map the behavior of a real PLC control device even more realistically.
  • the PLC sequence simulation device generates in each case a complete set of PLC control input data and writes it into the memory device before the PLC control device reads it out. Again, an atomicity of all PLC control input data of a period is reached again.
  • the device according to the invention comprises an interface for communication between the device Total simulation device and the PLC-Ablaufsimulations worn.
  • this interface for communication between the overall simulation device and the PLC sequence simulation device comprises a filter device that filters the amount of PLC data that the PLC sequence simulation device transmits to the interface, so that the total simulation device only extracts a subset of the quantity of the PLC process simulation device receives transmitted PLC data. Again, filtering is done so that the overall simulation device does not have to update the machine tool model too frequently, and thus a simulation in real time is made more difficult due to the high computational effort.
  • this filter device can again be configured via an input device, so that it is adjustable how much the filter device filters the PLC data.
  • the interface for communication between the overall simulation device and the PLC sequence simulation device comprises a synchronization device for synchronizing the communication between the overall simulation device and the PLC sequence simulation device.
  • All said interfaces may be configured as a remote interface.
  • a remote interface is adapted to allow remote communication between communication partners located in different locations. This makes it possible to distribute the individual devices over several computers. For example, it may be advantageous to run the overall simulation device and the visualization device on a first computer while the PLC control device, the CNC control device, and the PLC run simulation are executed on a second computer. This is advantageous because the overall simulation device and the visualization device require a great deal of computing capacity. As a result, that the interface between the PLC-Ablaufsimulations issued and the overall simulation device as well as the interface between the CNC control device and the overall simulation device are designed as a remote interface, a faster execution of the overall simulation can be achieved.
  • the device according to the invention comprises a collision detection device, which is set up to detect collisions between the machine tool including the operating means and the workpiece as a function of the total simulation data.
  • a collision detection device which is set up to detect collisions between the machine tool including the operating means and the workpiece as a function of the total simulation data.
  • the equipment includes, in particular, the tools used.
  • the device according to the invention comprises a travel range checking device for checking whether a predetermined position can be approached by the machine tool.
  • the predetermined position may, for example, result from the CNC part program or it may have been entered manually.
  • the travel range checking device it can be found, for example, whether a specified workpiece can be manufactured on a specific machine tool.
  • Salespeople can offer customers who intend to buy a machine tool a virtual demonstration of the machine tool, such as their laptop, and can visualize the customer how the desired workpieces are being made by that machine tool can and there is a check whether the machine tool is large enough and is suitable to produce the desired workpiece.
  • the visualization device is configured to display the overall simulation data at a speed that is at a constant ratio to the speed of the real process for machining a workpiece on a machine tool during a predetermined time period.
  • the visualization device can be set up to display the simulation data in real time. In this way, processes for processing a workpiece on a machine tool can be realistically visualized, so that the viewer gets a realistic impression of how the processing of a workpiece on a machine tool would take place in reality.
  • the means for providing control data is adapted to provide control data for executing a process for machining a workpiece on a five-axis machine tool.
  • the visualization of machining operations is particularly advantageous because it is particularly difficult for the user to imagine the machining process through the five axes.
  • the device according to the invention is set up to simulate a procedure for processing a workpiece on a first machine tool in a first time period and a procedure for processing a workpiece on a second machine tool in a second time period.
  • a CNC controller and a PLC controller relating to a second machine tool.
  • the simulability of different machine tools can be achieved in that the PLC program and the parameterization of the CNC controller can be replaced. This makes it possible, for example, different machine tools of the same machine tool manufacturer, such. Deckel-Maho-Gildehoff, easy and inexpensive to simulate.
  • the device according to the invention comprises a control selection device for selecting a control which is to be used in the context of the simulation of a process for processing a workpiece on a machine tool.
  • a controller may be selected, for example, by selecting a corresponding CNC controller and a corresponding PLC controller or by selecting a corresponding PLC program and corresponding parameters.
  • a user of the simulation device can conveniently select a controller and, based on the selected controller, simulate a process for processing a workpiece on a machine tool.
  • the device according to the invention has many advantages. It allows a realistic simulation of a machine tool. This makes it easier to detect collisions. In particular, such collisions that would be caused by PLC movements can be detected. Due to the holistic simulation, ie the inclusion of all aspects of the machine tool in the simulation, a better prediction of machine occupation times becomes possible. Users of the machine tool can be trained with the help of simulation. Training companies no longer necessarily have to buy a real machine tool, but can use the simulation. This reduces the capital investment. At the same time it is possible to simulate different machine tools and different controls of different control manufacturers with the help of the simulation. Damage to machine tools by inexperienced users is prevented because the virtual machine tool of the simulation can not be damaged. In addition, the simulation can be used for sales support.
  • Machine tools can be visualized on a laptop, for example, customers who want to buy a machine tool, for example.
  • conclusions can be drawn from the simulation results for the construction of machine tools. As a result, a steady improvement of the machine tools is possible. At the same time, new ideas for the construction of machine tools can be tried out safely on the model.
  • the invention comprises a method for simulating a sequence for machining a workpiece on a machine tool.
  • the method comprises the steps of providing machine tool data for producing a virtual image of a machine tool, providing workpiece data for generating a virtual image of at least one workpiece, providing equipment data for generating a virtual image, at least a resource, providing control data for executing a process associated with machining a workpiece on a machine tool, generating CNC data in response to the control data, generating PLC control output data, generating PLC simulation data, and PLC control Input data in dependence on the PLC control output data and the machine tool data, generation of total simulation data concerning the procedure for machining a workpiece on the machine tool in dependence on the CNC data, the PLC simulation data, the machine tool data, the workpiece data and the resource data and visualizing the Overall simulation data comprising the step of representing the process for machining a workpiece on the machine tool.
  • This method according to the invention for simulating a sequence for machining a workpiece on a machine tool offers the same advantages as the device according to the invention.
  • the method comprises the step of generating a CNC program from the source code of a CNC program of a real CNC controller.
  • the method may further comprise the step of providing a PLC program of a real PLC controller or the step of generating a PLC program from the source code of a PLC program of a real PLC controller.
  • the step of providing control data comprises the step of providing a CNC part program, wherein the CNC part program can be executed on a real machine tool.
  • the step of providing control data comprises the step of manually inputting control data by the user to change the operating state of the machine tool.
  • the step of manually inputting control data may include the step of inputting an override as the ratio between the feed rate according to the CNC part program and the changed feed rate when the CNC part program is executed on the machine tool.
  • the step of manually inputting control data may include the step of inputting control data for manual movement of spindle, head and / or table.
  • the step of manually inputting control data also includes the step of inputting control data for clamping workpieces.
  • the step of manually inputting control data comprises the step of inputting control data for specifying a zero point.
  • the step of manually inputting control data comprises the step of inputting control data to be inputted by the operator of the machine tool after turning on a real machine tool to achieve a ready operating state of the machine tool.
  • the inputs are made via a real control panel of a real machine tool comprising a CNC control panel and / or a PLC control panel.
  • the inputs can be made via a virtual control panel as a virtual image of a real control panel.
  • PLC control output data is generated in accordance with the control data.
  • the method comprises the steps of inputting a selection of a set within the CNC part program, generating total simulation data from the beginning of the CNC part program, and visualizing the total simulation data from the selected set, thereby scheduling a workpiece to be machined on the machine tool from the selected sentence.
  • the process for processing a workpiece on the machine tool is preferably carried out by displaying via a real CNC display device of a real machine tool.
  • the representation can take place via a virtual CNC display device as a virtual image of a real CNC display device of a real machine tool.
  • the total simulation data is visualized in three dimensions.
  • the supply of machine tool data step may comprise the step of providing kinematic data for describing the kinematic behavior of the machine tool.
  • the step of providing machine tool data may include the step of providing Machine tool element data for generating a virtual image of machine tool elements.
  • the step providing tool machine data comprises the step of providing configuration data for generating a virtual image of the machine tool as a function of the machine tool element data, the kinematic data and the configuration data.
  • the step of providing resource data comprises the step of providing tool data for generating a virtual image of at least one tool.
  • the step of providing resource data may include the step of providing clamping device data for generating a virtual image of at least one clamping device.
  • the method according to the invention comprises the step of parameterizing the step of generating CNC data and / or the step generating PLC control output data.
  • a parameterization is carried out with regard to at least one parameter from the group of travel range parameters, control behavior parameters, compensation parameters and tool magazine parameters.
  • the method according to the invention comprises the step of communicating CNC data from a CNC control device to an overall simulation device.
  • communicating CNC data from a CNC controller to a total simulation device is communicated via middleware.
  • the step of communicating CNC data from the CNC controller to the overall simulation device may include the step of converting non-object oriented CNC data to an object-oriented form.
  • the step of communicating CNC data from the CNC controller to the overall simulation device comprises the step of filtering the amount of CNC data such that the overall simulation device receives only a subset of the amount of CNC data communicated by the CNC controller.
  • the method of the invention may comprise the step of configuring the step of filtering the amount of CNC data by entering configuration data.
  • the method according to the invention comprises the step of communicating PLC control output data and PLC control input data between a PLC control device and a PLC execution simulation device.
  • the step of communicating PLC control output data and PLC control input data between the PLC control device and the PLC run simulation device may include the step of synchronizing the PLC control device and the PLC runtime simulation device using a semaphore.
  • the PLC control device writes all the PLC control output data generated in one period to a memory device before the PLC Procedure simulation device reads out the PLC control output data from the memory device.
  • the PLC execution simulator writes all the PLC control input data generated in one period to the storage device before the PLC user Control means reads the PLC control input data from the memory device.
  • the method according to the invention comprises the step of communicating PLC simulation data between the PLC run simulation device and the overall simulation device.
  • a middleware is communicated.
  • the step of communicating PLC simulation data between the PLC run simulation device and the overall simulation device may include the step of filtering the amount of PLC simulation data such that the overall simulation device receives only a subset of the set of PLC simulation data communicated from the PLC run simulation device.
  • remote communication takes place between communication partners located at different locations.
  • At least one of the communication steps comprises the step of invoking a method that a communication partner makes available to the other communication partner.
  • the method according to the invention comprises the step of detecting collisions between the machine tool including the operating means and the workpiece as a function of the overall simulation data.
  • the method according to the invention may comprise the step of checking whether a predetermined position can be approached by the machine tool.
  • the total simulation data is displayed at a speed that is at a constant ratio to the speed of the real process for machining a workpiece on a machine tool during a predetermined time period.
  • the total simulation data is displayed in real time.
  • control data for executing a process for processing a workpiece on a 5-axis machine tool are provided in the step of providing control data.
  • the method according to the invention comprises the step of providing a first CNC control device and a first PLC control device for simulating a sequence for machining a workpiece on a first machine tool and providing a second CNC control device and a second PLC control device for simulating a Procedure for machining a workpiece on a second machine tool.
  • the method according to the invention can provide the step of providing a first PLC program and first parameter for parameterizing the CNC control device for simulating a sequence for machining a workpiece on a first machine tool and providing a second PLC program and second parameter for parameterizing the CNC control device for simulating a sequence for machining a workpiece on a second machine tool.
  • the method according to the invention preferably comprises the step of selecting a control which is to be used in the context of the simulation of a procedure for machining a workpiece on a machine tool.
  • the invention further comprises a computer program product comprising a computer readable medium and a computer program stored therein, the computer program being stored in the form of a sequence of states corresponding to instructions adapted to be processed by a data processing means of a data processing device, such that a Device according to the invention is formed or the inventive method for simulating a process for machining a workpiece is carried out on a machine tool.
  • the PLC sequence simulation device described in the context of the description of the device according to the invention requires data on the temporal behavior of the simulated machine tool so as to be able to simulate the PLC sequences in terms of time. Therefore, the invention further includes a method for creating PLC machine tool sequence data, comprising the steps of: generating a sequence of PLC control data including at least one PLC control data, determining an initial condition and an end condition for each PLC control date of the sequence; Initial condition and the end condition relate to PLC control input data, providing a measuring unit, which is adapted to measure a time period between the occurrence of the initial condition and the occurrence of the end condition of each PLC control data of the sequence, executing the sequence PLC control data on a real machine tool by a real PLC control unit, wherein the measuring unit for each PLC control date of the sequence measures the time period between the occurrence of the initial condition and the occurrence of the end condition, generating PLC machine tool sequence data from the measurement data of the measuring unit and Saving the PLC machine tool sequence data includes.
  • a machine tool has actuators and sensors.
  • the actuators are controlled by the PLC controller by PLC control output data.
  • the PLC controller receives back PLC control input data.
  • the aim of the method for creating PLC machine tool sequence data is to generate data that indicates when the sensors of the real machine tool generate which PLC control input data in response to PLC control output data with which the PLC controller has driven the machine tool ,
  • the advantage of the method for creating PLC machine tool sequence data is that it is possible with this method to generate data that maps the real behavior of a machine tool in the execution of PLC control commands in terms of time.
  • the invention comprises a PLC sequence simulation device, which comprises a device for providing PLC machine tool sequence data, a clocking device for timing the sequence simulation of the machine tool, wherein the PLC sequences of the machine tool are described in particular in terms of time by the PLC machine tool sequence data, inputs for receiving of PLC control output data for controlling actuators of the machine tool, outputs for simulating output signals of sensors of the machine tool, an internal Process simulation means for generating PLC simulation data and PLC control input data in response to the PLC control output data received via the inputs, the PLC machine tool sequence data and the timing, and output means for outputting the PLC simulation data and outputting the PLC control Input data via the outputs.
  • a PLC sequence simulation device comprises a device for providing PLC machine tool sequence data, a clocking device for timing the sequence simulation of the machine tool, wherein the PLC sequences of the machine tool are described in particular in terms of time by the PLC machine tool sequence data, inputs for receiving of PLC control output data for controlling actuators of the machine
  • This PLC sequence simulation device is that it makes it possible to simulate the PLC sequences which take place on a real machine tool appropriately, in particular with regard to time.
  • the invention further comprises a computer program product comprising a computer readable medium and a computer program stored therein, the computer program being stored in the form of a sequence of states corresponding to instructions adapted to be processed by a data processing means of a data processing device, such that a A PLC sequence simulation device according to the invention is formed.
  • FIG. 1 shows an embodiment of a device according to the invention.
  • the user sees a first display device 101, on which a virtual CNC display device is shown.
  • a second display device 102 for displaying the virtual image of the machine tool.
  • the user has a real control panel 103 of a real machine tool available.
  • he can enter 104 data via a keyboard.
  • FIG. 2 shows an example of a virtual image of a machine tool in more detail. You can essentially see all the components you would also see on a machine tool.
  • the machine tool chamber 201 is visualized. Furthermore, one sees the processing head 202 of the machine tool and the corresponding table 203 for receiving the workpiece. Likewise, a CNC control panel 204 and a CNC display 205 can be seen. Even the door of the machine tool chamber 206 is shown including the type designation 207 of the machine tool and the window 208 of the door. This illustrates that the user of the device according to the invention is presented a very realistic image of a machine tool.
  • FIG. 3 shows the virtual image of the machine tool from FIG. 2 with an additional virtual control panel 301.
  • the virtual control panel includes a CNC panel 302 and a PLC panel 303.
  • An override knob is designated by reference numeral 304.
  • FIG. 4 shows that many elements of the machine tool can be hidden in this exemplary embodiment.
  • the machine tool chamber 201 is no longer visible, so that the user can see the table undisturbed.
  • the head of the machine tool 202 is retracted so that the clamped tool 401 dips into the workpiece 402.
  • the workpiece 402 is fixed on the table 203 by the tensioning means 403.
  • the removal 404 is visualized on the workpiece 402.
  • the user can see in this setting the entire sequence of movements for machining the workpiece on the machine tool.
  • Figure 5 illustrates that the user of the simulation device can be given a realistic impression of what he would see if he were standing at a real machine tool.
  • the user stands at the virtual machine tool and looks through the window 208 in the door 206 on the table 203 of the machine tool. There he sees the machining process on the workpiece 402. At the same time he sees the control panel 204 and the CNC display device 205.
  • FIG. 6 shows an example of a virtual CNC display device 601. More specifically, the virtual CNC display device 601 displays the CNC part program 602 to be executed that consists of individual sets 603. Furthermore, among other things, the position of the machine tool head can be seen in field 604.
  • FIG. 7 shows the schematic structure of an embodiment of a device according to the invention for simulating a sequence for machining a workpiece on a machine tool.
  • the Device 701 includes a first memory device 702 in which machine tool data is stored.
  • the first memory device comprises further memory devices.
  • a memory device stores kinematic data 703.
  • Another memory device stores machine tool element data 704.
  • Still another memory device included in the first memory device stores configuration data 705.
  • the device 701 includes a second memory device 706 that stores workpiece data.
  • resource data is stored in a third memory device 707, which is included in the device 701, resource data is stored.
  • the third memory device 707 comprises a further memory device 708 for storing tool data and a memory device 709 for storing clamping device data.
  • the device 701 comprises a device for providing control data 710, in the present example of control data for a five-axis machine tool.
  • This device for providing control data 710 comprises a memory device 711 in which at least one CNC part program is stored. Furthermore, the device for providing control data 710 comprises an input device 712.
  • the input device 712 comprises a multiplicity of further input devices.
  • the input device 712 includes an input device for inputting an override 713, an input device for inputting control data for clamping workpieces 714, an input device for inputting control data for executing a power-on procedure 715, an input device for manually inputting a travel path 716, an input device inputting control data to set a zero point 717, an input device to select a set within the CNC part program 718, and an input device to select a control 719 used in the simulation of a process of machining a workpiece on a machine tool should be used.
  • This list of input devices included in the input device 712 is not meant to be exhaustive, but merely serves to illustrate some aspects of the input device.
  • the device for simulating a process for processing a workpiece on a machine tool 701 comprises a CNC control device 720.
  • This CNC control device 720 comprises a CNC program 721.
  • the CNC control device comprises parameter 722, which controls the CNC Parameterize control device.
  • the device 701 includes a PLC controller 723 that includes a PLC program 724.
  • the PLC program maps a real PLC control of a real machine tool.
  • the device 701 includes a PLC run simulation device 725 for simulating the PLC operations on a machine tool.
  • the PLC controller 723 communicates with the PLC run simulator 725 via an interface 726.
  • This interface 726 includes a synchronizer 727 that causes the PLC controller 723 to always write a full set of PLC control output data before the PLC expires simulation device 725 reads them out.
  • the synchronizer 727 causes the PLC run simulator 725 to always write a full set of PLC control input data before the PLC controller 723 reads that PLC control input data.
  • the PLC run simulator 725 generates PLC simulation data, among other things.
  • This PLC simulation data communicates the PLC runtime simulation device 725 to an overall simulation device 731.
  • the communication of the PLC simulation data takes place via an interface 728 which comprises a filter device 729 and a synchronization device 730.
  • the filter device 729 ensures that the amount of PLC simulation data that is transferred from the PLC runtime simulation device 725 to the overall simulation device 731 can be set.
  • the synchronizer 730 synchronizes the communication between the PLC run simulator 725 and the overall simulator 731.
  • the overall simulation device 731 receives CNC data from the CNC control device 720 via the interface 732.
  • the interface 732 in turn comprises a filter device 733 and a synchronization device 734.
  • This filter device 733 causes the amount of CNC data transmitted by the CNC Control device 720 is given to the total simulation device 731, is adjustable.
  • the synchronizer 734 synchronizes the communication between the CNC controller 720 and the overall simulation device 731.
  • the overall simulation device 731 generates overall simulation data concerning the procedure for machining a workpiece on the machine tool. For the generation of the total simulation data, the overall simulation device 731 uses the PLC simulation data obtained from the PLC runtime simulation device 725, the CNC data obtained from the CNC control device 720, the machine tool data from the first storage device 702, the workpiece data the second storage device 706, and the resource data from the third storage device 707.
  • the generated total simulation data is output by the total simulation device 731 to a visualization device 735
  • Visualization device 735 includes a 3D display device 736. With the aid of the 3D display device 736, the visualization device 735 visualizes the machine tool including the workpiece and the resources and the processing sequence of the machine tool for processing the workpiece.
  • the device 701 comprises a parameterization device 737 for parameterizing the CNC control device 720 and / or the PLC control device 723.
  • a collision detection device 739 detects collisions between the machine tool including the resources and the workpiece depending on the total simulation data that it receives from the overall simulation device 731.
  • the device 701 includes a driving range inspection device 738 for checking whether a predetermined position can be approached by the machine tool.
  • FIG. 8 shows a first part of an exemplary embodiment of the method for simulating a sequence for machining a workpiece on a machine tool.
  • machine tool element data is provided.
  • machine tool kinematics data is provided.
  • configuration data is provided.
  • tool data is provided in step 804. This is followed by the provision of fixture data in step 805 and the provision of workpiece data in step 806.
  • the processes shown in FIG. 9 and FIG. 11 are initiated.
  • FIG. 9 shows a second part of an embodiment of the method for simulating a sequence for machining a workpiece on a workpiece Machine tool.
  • a CNC part program is provided.
  • control data for clamping a workpiece is input by the user.
  • the user inputs control data for setting a zero point in step 903.
  • the process illustrated in FIG. 10 is initiated.
  • FIG. 10 illustrates a third part of an exemplary embodiment of the method for simulating a sequence for machining a workpiece on a machine tool.
  • CNC data is generated.
  • This CNC data is communicated in step 1002.
  • PLC control output data is generated in step 1003.
  • the generated PLC control output data is communicated in step 1004.
  • PLC simulation data and PLC control input data are generated.
  • These PLC simulation data and PLC control input data are communicated in step 1006.
  • the procedure returns either to step 1003 or to step 1001.
  • the procedure shown in Figure 10 may be terminated, in particular by an input by the user or by reaching the end of the CNC part program.
  • FIG. 11 illustrates a fourth part of an exemplary embodiment of the method for simulating a sequence for machining a workpiece on the machine tool.
  • total simulation data is generated.
  • This overall simulation data is visualized in step 1102.
  • CNC data and PLC simulation data are received, if any.
  • a return is made to step 1101 where new overall simulation data is generated based on the newly received CNC data and the newly received PLC simulation data.
  • the procedure shown in Figure 11 may be terminated, preferably by an input by the user.
  • FIG. 12 shows an embodiment of a method according to the invention for creating PLC machine tool sequence data.
  • a sequence of PLC control data is created.
  • an initial condition and an end condition are determined for each PLC control date of the sequence.
  • a measurement unit is provided.
  • the sequence of PLC control data is executed in step 1204 on a real machine tool by means of real PLC control.
  • the time periods between the occurrence of the initial condition and the occurrence of the end condition for each PLC control date of the sequence are respectively measured by the measurement unit (step 1205).
  • One PLC control data is thus executed after the other, and it is measured when the initial condition and when the end condition occurs.
  • the time interval between the occurrence of the initial condition and the occurrence of the end condition is determined.
  • PLC machine tool sequence data is generated from the measurement data. This PLC machine tool sequence data is stored in step 1207.
  • FIG. 13 shows an exemplary embodiment of a PLC sequence simulation device according to the invention.
  • the PLC sequence simulation device 725 comprises a device for providing PLC machine tool sequence data 1301. This device for providing PLC machine tool sequence data 1301 may, for example, be an interface to the first memory device 702 in which the PLC machine tool sequence data are stored.
  • the PLC sequence simulation device 725 furthermore comprises a timing device 1302 for timing the sequence simulation of the machine tool, the PLC sequences of the machine tool being described in particular in terms of time by the PLC machine tool sequence data.
  • the PLC runtime simulation device 725 includes inputs 1303 for receiving PLC control output data from the PLC controller 723. Further, the PLC runtime simulation device 725 includes outputs 1304 to provide PLC control input data to the PLC controller 723. In addition, the PLC runtime simulation device 725 includes an internal runtime simulation device 1305 that provides PLC simulation data and PLC control input data in response to the inputs to the inputs 1303, the PLC machine tool run data as provided by the PLC machine tool run data providing device 1301 , and the timing of the timing device 1302 generates. The PLC simulation data is given to the overall simulation device 731 by the output device 1306, and the PLC control input data is output via the outputs 1304 by means of the output device 1306.
  • FIG. 14 illustrates an embodiment of a user interface to an embodiment of the PLC sequence simulation device according to the invention.
  • the user interface 1401 includes an output area 1402 in which the state of the inputs is displayed. Each entry there can be thought of as indicating whether there is a 0 (eg, 0 volts) or a one (eg, 5 volts) on an input wire. Whether a 0 or a 1 is present is indicated by the graphic icon in front of the entry.
  • the user interface 1401 further includes an output area 1403 in which the state of the outputs is displayed. Each of the entries shown there shows the state that is present on an output.
  • the user interface 1401 includes an output area 1404, in which the completion level of the PLC operations is displayed. For example, field 1405 indicates that the step of magnetically locking the car door is 100 percent.
  • FIG. 7 many technical features have been described in FIG. 7 that are optional.
  • a device according to the invention without a collision detection device and without a travel range checking device is conceivable. That these devices can be omitted to provide such a further embodiment is obvious to those skilled in the art, so that corresponding embodiments should be regarded as implicitly disclosed without these devices.

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EP07017075A 2006-09-15 2007-08-31 Procédé et dispositif destinés à la simulation de l'usinage d'une pièce sur une machine-outil Active EP1901149B1 (fr)

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CN101145047B (zh) 2011-08-10
US9360861B2 (en) 2016-06-07
CN101145047A (zh) 2008-03-19
JP5564098B2 (ja) 2014-07-30
US20080091394A1 (en) 2008-04-17
EP1901149A3 (fr) 2009-03-11
ES2353425T3 (es) 2011-03-02
JP2008071350A (ja) 2008-03-27
JP2013058268A (ja) 2013-03-28
DE502007005329D1 (de) 2010-11-25
EP1901149B1 (fr) 2010-10-13
DE102006043390A1 (de) 2008-03-27

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